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Well I was looking underneath my Cougar the other day and I found a weak spot on the bottom rocker guard near the drivers side rear tire. Its rotted right through. The rest of the cars in good shape. Its hollow so I was wondering do I scrape out as much rust as I can in and then bondo a patch in or what? I was pissed that my cat is rotting.
Thanks
Donnie
 

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Hey Don - what's up?

I noticed the SAME problem on my Cat this summer too - even though my car's only seen 2 winters, it's rusting through. Turns out - theres a drain hole at the back of the rocker, that gets pluged over the years. Then, water+salt+dirt+heat turn out once solid rockers to ****.

What I'm going to do, is SANDBLAST them, it's the ONLY way to remove the rust once and for all. But, since mine will not be shown (ground panels from SC are going on) I'm not going to do a perfect job of the body work. Just mud them up, sand them flat, and that's it.

As my car was in the shop getting work done, a body man from a Coast to Coast center and I were talking, and he said a job like that was $600 :eek:!!! I'm doing this job myself.

BTW - any pics of the Charger online :)?
 

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i found the exact same problem on my 93 sc, rear rockers rust out like hell....... when i got keyed earlier this summer i put the car in the body shop and had them rebuild the rear rockers..... total cost to repaint both sides of the car end to end and weld in new metal into rockers which was 2x thicker than the oem metal.....$2400

heres some before and after of the rockers, this is behind the drivers side door, the hole was around 15' long and the other side was just as long but not rotted through yet.

btw total replacement cost of rockers with new ones would have been over $800. $75 per rocker in parts and 6.5 hrs labor x $60 per rocker.... thats like $465 per side.
but because i was having the sides of the car painted anyway, and that the body shop guy is a friend of my dads, and that the front of the rockers on my car were solid, they were able to cut out all the rust and put in the new metal for like $400 bux or so... and another $300-400 to paint the ground effects and rockers.

Before:


After:
 

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same problem on the passenger side rocker right infront of the rear wheel. i can stick my finger in and to the sides. it's gotten a lot worse lately and now the paints bubbling around it too. the whole is already about 2"x1". can you unplug the drain hole easily? and will that temporarily stop the problem from getting any worse?
 

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The pluged drain is not the cause of the rust, as it's water/debris that gets stopped and stays in the rocker area. Once rust has started, there's no stopping it by just unpluging the hole. You have to remove the rusted areas, and fill them up with bondo.
 

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I would say the best way to prevent this problem is to get a 300 dollar beater car during the winter, and store your car when the snow flies. I don't have a garage, so i got a nice winter car cover, and drove my 89 subaru all winter long.
My car is from sawgrass ford in florida, and I live in buffalo, ny.

<img src=http://members.tccoa.com/justinh/side.jpg> <br>

JH
 

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My car IS wintered :( - I only drove it 2 years in the winter, and that got the rust started....

Damn Canuck winters :mad:.
 

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I see.
MN12's aren't of much use in the snow. I used to drive my 90 base around in the snow, and it was a death trap, even with 150 pounds of sand in the trunk, and four new snow tires.

JH

MercCougarXR7 said:
My car IS wintered :( - I only drove it 2 years in the winter, and that got the rust started....

Damn Canuck winters :mad:.
Code:
jh
 

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I bet with a trac-loc 8.8" with 3.73's you'd have problems on ice/snow :D!

I agree that these cars are death traps in the winter - no weight over the rear tires, and they slip+slide+spin all over the place...

BTW Justin - Gorgeous car :).
 

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94xr7 You and my bro would love eachother. Hes got a 74 charger with a 318 mini block. He probably wants to steal yours :) I will try and get some pictures of his as soon as he washes it good (probably never cause he doesn't even respect his own property nemore. O well. His car, his money, his rust.)
 

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Rockers

Basically, it's a bad design by Ford. I had 1 side replaced 2 years ago when I had my 1/4 panel replaced after someone hit me. Most cars have vented rocker panels, but for some reason Ford cheaped out on that. Planned obsolesence I suppose. As for handling badly in the snow....I never had a poblem....some studded snow tires always did the trick for me. And the 100 lb subwoofer box helps out too =)
 
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